Technical Description

Extended MTU lube oil system

MS61031/00E
SLU Name Sales Name
GG06R0400A1 MTU 6R400 GS
GG06R0400B1 MTU 6R400 GS
GG06R0400C1 MTU 6R400 GS
GG12V0400A1 MTU 12V400 GS
GG12V0400C1 MTU 12V400GS
GG08V4000A1 MTU 8V4000 GS
GG08V4000A2 MTU 8V4000 GS
GG12V4000A1 MTU 12V4000 GS
GG12V4000A2 MTU 12V4000 GS
GG16V4000A1 MTU 16V4000 GS
GG16V4000A2 MTU 16V4000 GS
GG20V4000A1 MTU 20V4000 GS
GG20V4000A2 MTU 20V4000 GS

© 2017 MTU Onsite Energy GmbH, Augsburg

The original document was created in the German language.
This publication including all of its parts is protected by copyright. Each instance of use requires the prior written consent of
MTU Onsite Energy GmbH. This applies in particular to duplication, dissemination, editing, translation, microfilming, and stor-
age and/or processing in electronic systems, including databases and online services.
All of the information presented in this publication was current and up-to-date at the time of publishing. MTU Onsite Energy
GmbH reserves the right to make changes to, delete, or supplement the provided information and data as needed.
 Table of Contents
1 Lube Oil System 1.6 Control system for extended MTU lube oil
system via MMC (genset control system) 13
1.1 Design recommendation for extended MTU 1.7 Customer-provided services 15
lube oil system with oil circulation volume 4 1.8 Site conditions 16
1.2 Properties and dimensions 5 1.9 Ambient conditions 17
1.3 Design of extended MTU lube oil system 1.10 Further laws, specifications, guidelines, etc. 18
(P&I diagram) 7 1.11 Electrical connections – Interfaces 19
1.4 Equipment of extended MTU lube oil
system, hardware components and
2 Appendix A
hydraulic interfaces 10
1.5 Components of the extended MTU lube oil 2.1 Index 22
system – Description 11
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 1 Lube Oil System
1.1 Design recommendation for extended MTU lube oil system
with oil circulation volume
To extend the oil change intervals and minimize the downtimes, we recommend the installation of an extend-
ed MTU lube oil system with extended circulation volume per genset.
The extended MTU lube oil system uses a jacketed lube oil tank with a two-chamber design. A switch is
made between the two chambers to change the oil. This means that the supply of fresh oil and disposal of
used oil can be separated temporally from one another.
The tank is connected to a genset by means of a refill line and a used oil line.
During operation, a small amount of the lube oil is continuously sprayed off via the used oil line into the
chamber of the double tank that is in operation (MTU lube oil spray-off system). This results in a lowering of
the lube oil level in the engine oil pan.
When the refill contact is reached, a signal is issued to the genset control system that monitors the lube oil
level in the engine oil pan.
This results in opening of the refill solenoid valve at the extended MTU lube oil system. The engine oil pan is
filled up by the lube oil pump via the refill line up to the upper trip point.
The advantage of this system is that the oil change interval is considerably lengthened and can be adapted to
the maintenance intervals. The additional oil volume can be positioned as required in the existing installation
compartment.
If the extended MTU lube oil system and its activation are part of the MTU scope of delivery, they will also be
included in the Declaration of Conformity or Declaration of Incorporation. The system has been optimized for
use in conjunction with MTU gensets and has fully proven its value with the following advantages:
• Optimized downtimes and extended maintenance intervals
• Integrated in the genset control system and thus an element of the safety concept
• Design as a complete system makes planning simpler
• WHG-certified components (German Water Resources Act)
• Complete documentation available in advance
• Optimized delivery time of complete genset due to reduced coordination effort
• Reduced assembly complexity due to preassembled components
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 1.2 Properties and dimensions

Figure 1: Extended MTU lube oil system consisting of lube oil double tank with preassembled monitoring
sensors and lube oil pump (example)

MTU lube oil system 2x 2000 l

Length (A) approx. 1500 mm
Total width (D) approx.1010 mm
Total width incl. equipment (E) approx.1310 mm
Tank height (C) approx. 1500 mm
Tank height incl. equipment and ventilation (B) Approx. 1950 mm
Empty weight incl. add-on components approx. 750 kg
Filling volume 95% of the tank volume (1930 l per chamber)
Interior coating None (raw / oiled)
Exterior coating 2-comp. paintwork RAL 7032 (pebble gray) for in-
door installation
Design Upright (on feet), cubic tank, jacketed, with crane
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eyelets (for empty transport)

MTU lube oil system 2x 1000 l

Length (A) Approx. 1000 mm
Total width (D) approx. 760 mm
Total width incl. equipment and ventilation (E) approx.1060 mm
Tank height (C) approx. 1500 mm
Tank height incl. equipment and ventilation (B) Approx. 1950 mm

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 Empty weight incl. add-on components approx. 520 kg
Filling volume 95% of the tank volume (930 l per chamber)
Interior coating None (raw / oiled)
Exterior coating 2-comp. paintwork RAL 7032 (pebble gray) for in-
door installation
Design Upright (on feet), cubic tank, jacketed, with crane
eyelets (for empty transport)

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 1.3 Design of extended MTU lube oil system (P&I diagram)

Figure 2: P&I diagram of extended MTU lube oil system for Series 4000
No. Designation Function
1 Genset
2 Spray-off line
3 Lube oil
4 Used oil
5 Oil priming
6 Collecting trough with leak monitoring LZAH
7 Genset
8 Customer-side
9 Ball valve DN25 Manual draining after genset
10 Ball valve DN25 Filling, supply line before genset
11 Ball valve DN15 Spray-off system shutoff
12 Ball valve DN25 Engine filling
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13 Ball valve DN25 Tank filling from barrel

14 Ball valve DN25 Draining into barrel
15 Ball valve DN25 Filling from barrel
16 Vacuum leak indicator LAI
17 Level indicator LI
18 Mounting bracket with overfill protection and LH
tank vehicle connector
19 Overfill protection LZAH

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 No. Designation Function
20 Tank vehicle connector LJ
21 Steel tank, jacketed, 2-chamber design Tank 1 (1000 to 2000 l)
22 Steel tank, jacketed, 2-chamber design Tank 2 (1000 to 2000 l)
23 Preassembled tank system

Table 1: Key to extended MTU lube oil system

Figure 3: P&I diagram of extended MTU lube oil system for Series 4000
No. Designation Function
1 Genset
2 Spray-off line Continuous spray-off of lube oil
3 Lube oil Lube oil supply
4 Used oil Used oil draining during oil change
5 Not applicable
6 Collecting trough with leak monitoring LZAH
7 Genset
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8 Customer-side
9 Ball valve DN25 Manual draining after genset
10 Ball valve DN25 Filling, supply line before genset
11 Ball valve DN15 Spray-off system shutoff
12 Ball valve DN25 Engine filling
13 Ball valve DN25 Tank filling from barrel
14 Ball valve DN25 Draining into barrel
15 Ball valve DN25 Filling from barrel

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 No. Designation Function
16 Vacuum leak indicator LAI
17 Level indicator LI
18 Mounting bracket with overfill protection and LH
tank vehicle connector
19 Overfill protection LZAH
20 Tank vehicle connector LJ
21 Steel tank, jacketed, 2-chamber design Tank 1 (1000 to 2000 l)
22 Steel tank, jacketed, 2-chamber design Tank 2 (1000 to 2000 l)
23 Preassembled tank system
24 Ball valve DN25 Manual draining before tank

Table 2: Key to extended MTU lube oil system

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 1.4 Equipment of extended MTU lube oil system, hardware
components and hydraulic interfaces

Figure 4: Elements of extended MTU lube oil system: Lube oil double tank with preassembled monitoring
sensors and lube oil pump (example)
1 Inspection opening, safety 5 Level indicator, sleeve w/ 9 Overfill protection, sleeve
assembly for pressure com- female thread, float level in- w/female thread, reducer
pensation, flange cover with dicator type 1.000 Un- 2"x3/4", overfill protection,
bursting disk / DN600 imes / G2" level transmitter type
2 Leak indicator, sleeve w/ 6 Filling, sleeve w/female 76 A / G2"
female thread, vacuum leak thread, filling pipe 2", 10 Extraction with pump,
indicator / G1/2" (l = 100 mm) bolted,angle sleeve w/female thread,
3 Vent, sleeve w/female 45°, tank vehicle coupling flange dia. 160 mm, suction
thread, pipe neck 2" with DN50 / G2" pipe 1" / G1"
vent hood / G2" 7 Extraction system, sleeve 11 Mounting bracket with over-
4 Return line, sleeve w/ w/female thread, flange fill protection, level limiter
female thread, reducer dia. 160 mm, extraction type NB 220 OSF & AE-203
2"x1" / G1" pipe 2", angle 45°, tank ve- and tank vehicle connector
hicle coupling DN50 / G2" type 907 Z
8 Pump group with collecting
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trough and leak monitoring

Extended MTU lube oil system: Description of hydraulic interfaces

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 1.5 Components of the extended MTU lube oil system –
Description
Components
• Jacketed lube oil tank in two-chamber design of welded steel with type test
• Including preassembled and wired safety fittings (only between overfill protection and warning device, wir-
ing between warning device and MMC cabinet provided by customer), mechanical vacuum monitoring
• Including preassembled pump group and monitored collecting trough
• Certification according to Water Resources Act (WHG)
• Material: Standard steel, primed and varnished, color: RAL 7032 (pebble gray)

Lube oil tank leak monitoring Design type-approved, permanently effective tank in-
termediate space monitoring based on the vacuum
principle
Vacuum gauge as a leak indicator in the area of the
tank jacket with approval document
Manufacturer: Krampitz
Model: KüR 5
Lube oil tank overfill protection All components installed on tank, connection option
for customer-provided flashing lamp and horn.
Manufacturer: Fafnir
Measuring transmitter type: NB 220 QSF 24 V
Level transmitter type:
• 76 A, probe length 200 mm
• Connection w/G3/4" male thread
Wall fitting type: 907 Z
Lube oil pump Medium: Lube oil as fresh oil and used oil
Max. operating pressure: 5.0 bar (overpressure)
Temperature range of lube oil during operation: +15
to +95 °C
Ambient temperature up to 60 °C
Lube oil pump incl. associated pump foot installed
ready for operation on tank
Manufacturer: Rickmeier GmbH
Model:
• Gear pump unit R25/10 FL−Z−DB−SO
• Gear pump R25/10 L−Z−DB16−W−G3/4−R−SO
Collecting trough for lube oil pump The collecting trough is installed on the pump group
on the tank. Collecting trough made of black steel,
welded design, primed and varnished. An oil leak
monitor is installed in the collecting trough.
Manufacturer: Endress+Hauser
Model: Liquiphant T, FTL31 AA4U 2AAWBJ
Key switch Normally open contact 24 VDC contact rating ≥ 6 A
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Pre-wiring All components installed on the tank are electrically

wired and have had their operation checked before-
hand.
Check and setting of overfill protection with test re-
cord

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 Pipework between pump and lube oil tank PN 10 pipework, black, welded, for diameter see P&I
diagram. The suction side of the pump must be pro-
vided with a sight glass (by way of a T-piece). The
sight glass is included in the scope of delivery.
• Pressure test in accordance with MTU specifica-
tion
• Flush pipelines thoroughly after assembly and put
into operation
• Including records and inventory documents
Connections One inspection opening per tank with cover and in-
stallation of the tank equipment and removable lines
(screw-coupling)
• Screwed in suction pipe 1" without foot valve,
routed to tank bottom
• Vent neck 2" with hood
• Filling and exhaust vent with tank vehicle coupling
for filling pipe 2",
protruding 10 cm into tank, extraction pipe 2"
routed to tank bottom,
filling and suction pipe closure 2"x 21/2" with an-
gle 2" 45° male thread
• 2 spare sleeves 2" with plugs per tank
• Mechanical level gauge
• 6x blanking plugs 2"

Table 3: Description of components

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 1.6 Control system for extended MTU lube oil system via MMC
(genset control system)
The activation of the lube oil supply is divided into the following areas:
• Control system for lube oil pump for lube oil supply and disposal
• Monitoring of tank system
• Monitoring of pumps for collecting trough at extended MTU lube oil system

Activation of lube oil pump for genset refilling

The MMC switches on the lube oil pump for fresh oil supply at the same time as the lube oil solenoid valves
at the genset.
This pump can be operated in manual mode via the visualization. The lube oil pump is used in automatic
mode for oil replenishment and can be used in manual mode for filling the oil pan.
The following I/O signals are available in the MMC:
Designation Type (from perspective of MMC) Function
Digital in- Digital Analog In- Analog
Power rating
put output put output
Activation of fresh oil 400 VAC, 0.75 kW, High ac-
- x - -
pump 1.8 A tive
High ac-
Fresh oil pump faulty x - - - -
tive

In the 400 and 4000 Series, the signals and power sections are integrated in the MMC control cabinet.
In the 400-C1 Series, the power sections can be integrated in the "MTU Onsite Energy" auxiliary drive field,
or integrated by the customer.
For details of the activation, refer to the circuit diagrams in the plant.
With the extended 400 Series (Series 400-C1), the integrated extended MTU lube oil system is
preferred. This is available in the MTU scope of delivery as an option.

Electrical controls of the extended MTU lube oil system

Lube oil refilling can be initiated either at the MMC visualization or by means of the key switch installed di-
rectly at the MTU lube oil system.
The key switch is the preferred method if one of the tanks at the extended MTU lube oil system is to be filled
or drained.
With the 4000 Series, the used oil pump is used in manual mode for draining the genset oil pan. When doing
this, draining of the genset oil pan is initiated via the visualization of the MMC.
For details of the activation, refer to the circuit diagrams in the plant.
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Activation of the used oil solenoid valve (only for 4000 Series)
This valve for draining the genset oil pan is activated via manual mode of the used oil pump. The solenoid
valve in the 4000 Series is always installed on the genset baseframe.

Monitoring of the extended MTU lube oil system

All safety transmitters installed in the extended MTU lube oil system are recorded in the MMC and the corre-
sponding pumps are activated or deactivated. Furthermore, operational and fault messages are generated.
With a supply voltage of 24 V DC , the following I/O signals are available in the MMC.

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 Designation Type (from perspective of MMC) Function
Digital in- Digital Analog In- Analog
Floating contact
put output put output
Overfill protection
Low ac-
tank 1 (Fafnir x - x - -
tive
NB220QSF)
Overfill protection
Low ac-
tank 2 (Fafnir x - x - -
tive
NB220QSF)
Pump group leakage Low ac-
x - x - -
monitoring Liquiphant tive

Low active means that the message is issued if the switching contact is opened, or is pending
with opened / deactivated switching contact.

For details of the activation, refer to the circuit diagrams in the plant.

Monitoring MTU lube oil spray-off system

The operation of the MTU lube oil spray-off system is monitored as follows:
Within a defined time, the refill contact must be tripped at least once. This guarantees that the complete oil
volume is recirculated.

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 1.7 Customer-provided services
The system is delivered in the form of loose components. Apart from unloading and installation, the
following additional services are required:

• Approval procedure for installation and usage

• Check that the extended MTU lube oil system fully complies with the approval requirements
• Pipework between lube oil tank and genset in black welded or stainless steel design
• Leak check of pipework
• Wiring between the extended MTU lube oil system and MTU control system and electrotechnical check
prior to commissioning
• Filling with lube oil in accordance with MTU Fluids and Lubricants Specifications
No claim with regard to completeness
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 1.8 Site conditions
The extended MTU lube oil tank system can be transported when drained by a forklift truck, lift truck or a
crane and can thus be flexibly installed in the machinery building.
Prior to initial operation, the assembly, installation, pipework and electrical system must be correctly de-
signed, checked and documented.

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 1.9 Ambient conditions
The MTU lube oil system is intended exclusively for installation inside a building.
• Minimum ambient temperature for operation
15 °C
• Maximum lube oil temperature
95 °C
• Maximum pressure for pipework
5 bar (overpressure)
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 1.10 Further laws, specifications, guidelines, etc.
Please note the following points:
• Laws, specifications, guidelines, etc., such as the Water Resources Act
• Ordinance on Installations for the Handling of Substances Hazardous to Water
• Hazardous Substances Ordinance
• Flammable Liquids Ordinance
• Ordinance on Industrial Safety and Health
• Accident Prevention Regulations
• Closed Substance Cycle Waste Management Act
• Waste Oils Regulation
No claim with regard to completeness

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 1.11 Electrical connections – Interfaces

Figure 5: Example of the electrical design of the oil leak monitoring

1 Oil leak monitoring, pump 2 Key button, lube oil pump
group manual ON / OFF
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 Figure 6: Example of the electrical design of the lube oil pump protection
1 Set to 3 Lube oil pump 5 Oil leak monitoring, pump
2 Lube oil pump ON 4 Identification plate group

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 Figure 7: Example of the electrical design of the overfill protection
1 Lube oil tank probe 3 Output for unacknowledged 5 Tank vehicle connector for
2 Overfill protection message lube oil tank
4 Overfill protection, lube oil
tank, enable truck filling
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 2 Appendix A
2.1 Index
A P
Ambient conditions  Properties 
– Lube oil system  17 – Dimensions  5

C S
Components  Site conditions 
– Extended lube oil system  11 – Lube oil system  16
– Unloading and installation  15
Control system / operating elements  U
– Extended lube oil system   Unloading and installation 
– Monitoring  13 – Components  15

D
Design 
– Extended lube oil system  7
Designs 
– Oil circulation volume  4
Dimensions 
– Properties  5

E
Equipment 
– Lube oil system  10
Extended lube oil system 
– Components  11
– Control system / operating elements  
– Monitoring  13
– Design  7

I
Interfaces 
– Lube oil system  19

L
Laws, specifications, guidelines 
– Lube oil system  18
Lube oil system 
– Ambient conditions  17
– Equipment  10
– Interfaces  19
DCL-ID: 0000045384 - 001

– Laws, specifications, guidelines  18

– Site conditions  16

M
Monitoring 
– Extended lube oil system  
– Control system / operating elements  13

O
Oil circulation volume 
– Designs  4

22 | Appendix A | MS61031/00E 2017-01